Jeep Wrangler TJ. Manual - part 235
(10) Install yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(11) Tighten the nut to 271 N·m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(12) Using Spanner Wrench 6958 and a torque
wrench set at 475 N·m (350 ft. lbs.), (Fig. 75) slowly
tighten the nut in 6.8 N·m (5 ft. lbs.) increments
until the rotating torque is achieved. Measure the
rotating torque frequently to avoid over crushing the
collapsible spacer (Fig. 76).
CAUTION: If more than 475 N·m (350 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(13) Check bearing rotating torque with a inch
pound torque wrench (Fig. 76). The pinion gear rotat-
ing torque should be:
• Original Bearings: 1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings: 2 to 4 N·m (20 to 35 in. lbs.).
(14) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(15) Invert the differential case in the vise.
(16) Install new ring gear bolts and alternately
tighten to 136 N·m (100 ft. lbs.) (Fig. 77).
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(17) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern) for procedure.
Fig. 75 PINION YOKE WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 76 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 77 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ
REAR AXLE - 194RBI
3 - 117
PINION GEAR/RING GEAR (Continued)